01_Inghilterra_059311 27-12-2007 17:52 Pagina 1 WORKSHOP MANUAL
01_Inghilterra_059311 27-12-2007 17:52 Pagina 2
01_Inghilterra_059311 27-12-2007 17:52 Pagina 3 INTRODUCTION This publication has been designed to assist authorized service personnel of Betamotor Workshops in maintaining and repairing the vehicle referred to in the manual. Familiarity with the specifications contained herein is a key factor in the technical training of operators. In order to make the manual easy to read and understand, the different paragraphs are marked with icons that point out the subject dealt with.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 4 GENERAL CONTENTS 1 General information 2 Specific tools 3 Tightening torques - Specifications Recommended products 4 Maintenance 5 Bodywork and fittings 6 Engine 7 Carburettor 8 Front suspension/wheel 9 Rear suspension/wheel 10 Braking system 11 Electrical system 4 Workshop manual RR 4T - 400 - 450 - 525
01_Inghilterra_059311 27-12-2007 17:52 Pagina 5 1 GENERAL INFORMATION Pag.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 6 CONTENTS HOW TO CONSULT THE MANUAL GENERAL CONTENTS . . . . . . Arrangement of subjects . . . . Description of operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. Chap. Chap. Chap. 1 1 1 1 - 7 7 7 7 PURPOSE OF THE MANUAL . . . . . . . . . . . Chap. 1 - 7 Updates . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 7 TERMS AND SYMBOLS CONVENTION . . . . . . . . . . . . . . Chap. 1 - 8 . . . . . . . . . . . .
01_Inghilterra_059311 27-12-2007 17:52 Pagina 7 HOW TO CONSULT THE MANUAL GENERAL CONTENTS Arrangement of subjects The manual is divided into chapters that cover the main subassemblies of the vehicle. To make the different chapters easy to find, the pages of each chapter bear a reference mark that is aligned with the related title in the general contents.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 8 TERMS AND SYMBOLS IMPORTANT NOTE 8 When performing these operations, flammable vapours can be released and metal parts can be ejected at high speed. It is therefore necessary to: - Avoid working near sparks or open flames. - Wear protective clothing. - Wear protective goggles. Whenever a worn cylinder part needs to be replaced, we recommend checking and if necessary replacing all the parts that are related to it.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 9 CONVENTION In order to clarify the left/right convention used in this manual, a diagram of the vehicle and engine are provided below with an indication of how the two sides are referred to in the manual.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 10 SAFETY WARNING The information contained in this paragraph is designed to minimize the risks the operator runs when working on the vehicle. Carbon monoxide • Exhaust gases contain carbon monoxide (CO), a poisonous gas that can cause loss of consciousness and even death. • Before starting the engine, ensure that the area is well ventilated. Never run the engine indoors.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 11 Brake fluid • The brake fluid is highly corrosive. • Avoid contact with the eyes, the skin and the mucous membranes. • In case of skin contact, immediately take off any contaminated clothes or footwear and wash abundantly with soap and water. • In case of eye contact, rinse abundantly with water and seek medical attention.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 12 NOTES The information contained in this paragraph is designed to prevent damage to the vehicle. • Thoroughly clean the vehicle before removing parts. • After removing parts, clean them and place them in containers taking care to observe the order of removal. • Always use special tools whenever necessary or directed. • Always use glues, sealants and lubricants as directed, observing the indications about their specifications.
01_Inghilterra_059311 27-12-2007 17:52 Pagina 13 OPERATING SPECIFICATIONS VEHICLE IDENTIFICATION The frame number is stamped on the right side of the head tube. The engine number is stamped on the upper crankcase half, next to the swingarm.
01_Inghilterra_059311 14 27-12-2007 17:52 Pagina 14 Workshop manual RR 4T - 400 - 450 - 525
02_Inghilterra_059311 27-12-2007 17:57 Pagina 1 SPECIAL TOOLS 2
02_Inghilterra_059311 27-12-2007 17:57 Pagina 2 Code Description 3625132 UNIVERSAL ENGINE MOUNTING TOOL 3625198 RACING ENGINE BRACKET 3625202 CHAIN LINK ASSEMBLING TOOL 3625200 WATER PUMP SEAL FITTING TOOL POMPA ACQUA 2 3625097 SPECIAL RING PLIERS 3625203 PRIMARY DRIVE PULLER 3625174 PISTON RING ∅ = 75 MM 3625175 PISTON RING ∅ = 89 MM 3625384 PISTON RING ∅ = 95 MM Workshop manual RR 4T - 400 - 450 - 525
02_Inghilterra_059311 27-12-2007 2 - Special tools 17:57 Pagina 3 Code Description 3625001 LOCTITE 243 BLUE 6CCM 3625081 BUSH PULLER 3625082 INNER BEARING PULLER 12-16MM 3625083 INNER BEARING PULLER 18-23MM 3625084 INNER BEARING PULLER 5-7MM 3625204 VALVE GUIDE CHECKING TOOL 3625207 INNER CLUTCH RING FITTING TOOL 3625208 SHAFT PROTECTING COVER 3625205 GEAR PULLER 3625201 VALVE SPRING TOOL 3625193 INNER RING FITTING TOOLS NJ206 Release 01 Date 09/2007 3
02_Inghilterra_059311 4 27-12-2007 17:57 Pagina 4 Code Description 3625238 CHECKING SPANNER 3625173 FLYWHEEL PULLER 3625000 SILICONE (TUBE) 3625098 TIMING CHAIN FITTING TOOL 3625209 SPARK PLUG SPANNER 13/16 3625090 CLUTCH BLEEDING OIL SYRINGE 3625194 LOCTITE 648 GREEN 24ML 3625199 CLUTCH PULLER Workshop manual RR 4T - 400 - 450 - 525
02_Inghilterra_059311 27-12-2007 2 - Special tools 17:57 Pagina 5 Code Description 3625206 CARBURETTOR ADJUSTING SPANNER Release 01 Date 09/2007 5
02_Inghilterra_059311 6 27-12-2007 17:57 Pagina 6 Workshop manual RR 4T - 400 - 450 - 525
03_Inghilterra_059311 27-12-2007 18:00 Pagina 1 TIGHTENING TORQUES SPECIFICATIONS RECOMMENDED PRODUCTS 3
03_Inghilterra_059311 27-12-2007 18:00 Pagina 2 CONTENTS SPECIFICATIONS - ENGINE . . . . . . . . . . . . Chap. 3 - 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . Chap. 3 - 3 CARBURETTOR TUNING . . . . . . . . . . . Chap. 3 - 4 TIGHTENING TORQUES . . . . . . . . . . . . Chap. 3 - 5 FITS, WEAR LIMITS . . . . . . . . . . . . . . . . Chap. 3 - 6 STANDARD ADJUSTMENTS - FORK Chap. 3 - 6 STANDARD ADJUSTMENTS - SHOCK ABSORBER . . . . . . . . . . . Chap. 3 - 6 SPECIFICATIONS - FRAME . . . . . . . . . . . .
03_Inghilterra_059311 27-12-2007 18:00 Pagina 3 SPECIFICATIONS - ENGINE SPECIFICATIONS Engine 400 Type 450 525 single-cylinder, 4-stroke, liquid-cooled, with countershaft and electric start Displacement Bore/stroke Compression ratio Fuel 398 cc 448 cc 510 cc 89 / 64 mm 89 / 72 mm 95 / 72 mm 11 : 1 11 : 1 11 : 1 unleaded premium fuel with a minimum of 95 RON Valve gear 4 rocker-operated valves and 1 overhead camshaft driven by single chain Camshaft 5532 590/5521 590/5521 590/5521 D
03_Inghilterra_059311 27-12-2007 18:00 Pagina 4 SPECIFICATIONS - ENGINE CARBURETTOR TUNING 400/450 525 Carburettor type Keihin FCR-MX 39 Keihin FCR-MX 39 Carburettor code 3900A 3900B 178 178 OBDVR OBDVT Idling jet 42 42 Main air jet 200 200 Idling air jet 100 100 Needle valve position 3. 3. Starting jet 85 85 1,25 turns 1,25 turns 15 15 throttle valve stop throttle valve stop 858 / 2,15 mm 858 / 2,15 mm Main jet Jet needle Fuel mixture adj.
03_Inghilterra_059311 27-12-2007 18:00 Pagina 5 SPECIFICATIONS - ENGINE TIGHTENING TORQUES Description Type Tightening M6 10 N·m Oil drain screw M12x1.5 20 N·m Short oil unit socket-head screw M16x1.5 10 N·m Long oil unit hexagonal-head screw M20x1.5 15 N·m M5 6 N·m M12x1.
03_Inghilterra_059311 27-12-2007 18:00 Pagina 6 SPECIFICATIONS - ENGINE FITS, WEAR LIMITS Crankshaft Small end bearing Cylinder 450/450 Cylinder 525 Piston 400 Piston 450 Piston 525 Luce segmento Valves Valve springs 450 / 525 /400 Oil pump By-bass valve Clutch plates Gear shafts Rocker arm shafts Countershafts axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,1 - 0,2 mm offset between shaft sections . . . . . . . . . . . . . . . . . . . .max.
03_Inghilterra_059311 27-12-2007 18:00 Pagina 7 SPECIFICATIONS - CYCLE PARTS 400/450/525 Frame Single-beam, molybdenum steel frame with double cradle split over exhaust port Fork “MARZOCCHI” hydraulic upside-down fork (leg Ø 45) Front/rear suspension travel 290/300 mm Rear suspension SACHS monoshocks with progressive leverage Front brake Floating steel disc Ø 255 mm with floating caliper Rear brake Steel disc Ø 240 mm with floating caliper Brake discs Wear limit 0.
03_Inghilterra_059311 27-12-2007 18:00 Pagina 8 HOMOLOGATION E3 1 The latest models are E3 type-approved and they differ from prior approvals in that three devices have been introduced: AIS valve It is called AIS 1 and it is an air intake system which allows to complete the combustion of some unburned fuels remaining from the thermodynamic cycle.
03_Inghilterra_059311 27-12-2007 18:00 Pagina 9 SPECIFICATIONS - FRAME TIGHTENING TORQUES 4 fork foot screws M6 10 N·m Front brake caliper M8 CH10 Loctite 243 + 30 N·m Front brake disc M6 Loctite 243 + 15 N·m Rear brake disc M8 CH10 Loctite 243 + 20 N·m Upper fork plate clamping screws M8 CH10 20 N·m Lower fork plate clamping screws M8 CH10 20 N·m Rear wheel spindle flange nut M20x1.5 CH27 90 N·m Swingarm pin hexagonal nut M16x1.
03_Inghilterra_059311 10 27-12-2007 18:00 Pagina 10 Workshop manual RR 4T - 400 - 450 - 525
04_Inghilterra_059311 27-12-2007 18:10 Pagina 1 MAINTENANCE 4
04_Inghilterra_059311 27-12-2007 18:10 Pagina 2 CONTENTS PLANNED MAINTENANCE . . . . . . . . . . . . Chap. 4 - 3 How to clean parts . . . . . . . . . . . . . . . . Chap. 4 - 4 Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 4 Part fitting guidelines . . . . . . . . . . . . . . Chap. 4 - 4 SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 20 Fork Adjusting the rebound damping . . Chap. 4 - 20 Adjusting the compression damping . Chap.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 3 PLANNED MAINTENANCE Interval hours (h) 3 after/every 15 fuel (litres) 20 100 Air filter (after each off-road ride) C C Valves K K Spark plug (replace every 30 hours) - K Idle speed K K Throttle cable play K K Clutch K K Engine oil R R Engine oil filter R R Engine oil gauze strainer C C Exhaust pipe bolts - T Brakes K K Brake lines (replace every 4 years) K K Brake fluid (renew every 2 years) K K Tyres - K St
04_Inghilterra_059311 27-12-2007 18:10 Pagina 4 How to clean parts Clean all parts with suitable biodegradable solvents and then dry them with compressed air. Clean the assemblies before disassembling them as well as the individual parts after disassembly. Also clean each part before reassembly. Fits To keep the engine in perfect running order, ensure that all fits are within the prescribed tolerances.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 5 Oil circuit Oil pump 3 sucks the engine oil from the gearbox oil sump through long oil unit 4. The oil flows through oil line 5 into the cylinder head to camshaft lubrication point 6. The oil quantity is adjusted by means of oilway screw 7. A pipe branches off to long oil unit 8, where the coarser particles are filtered from the oil. The oil then comes to short oil unit 9, which filters off the finer particles.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 6 Cleaning the short oil unit Short oil unit 1 is fitted into socket-head screw 2 on the lower side of the engine. Insert an Allen key into the socket and unscrew the oil drain screw. Remove the oil unit, thoroughly clean its components and blow them with low-pressure compressed air. Check the O-rings for damage and if necessary replace them. Replace the oil unit with the screw and tighten the latter to 10 N·m.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 7 Replacing the oil filter Remove screw 1 and place a container under the engine to collect the drained oil. Remove the four screws 2 and take off the two oil filter covers. 1 2 ENVIRONMENT: Dispose of spent oils in compliance with applicable laws. 2 Using a pair of Seeger ring pliers, pull out the two filter elements 3 from the crankcase. Clean the oil filter covers, the O-ring sealing surfaces and the crankcase.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 8 Checking the front brake fluid level Check the brake fluid level by looking through sight A. The level should never fall below the mark in the sight. Restoring the front brake fluid level To restore the brake fluid level, unscrew the two screws 1, lift cap 2 and pour in fresh fluid (IP DOT 4) until the level is 5 mm below the upper rim of the reservoir. A IMPORTANT: We recommend using DOT 4 brake fluid. Should this fluid be unavailable, use DOT 5.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 9 Checking the rear brake fluid level Ensure the brake fluid level by looking through sight D. The level should never fall below the mark in the sight. Restoring the rear brake fluid level To restore the brake fluid level, unscrew cap 3 and pour in fresh fluid (IP DOT 4) until the level reaches the mark in sight D. D IMPORTANT: We recommend using DOT 4 brake fluid. Should this fluid be unavailable, use DOT 5.1 instead.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 10 Checking the front brake pads To check the wear of the front brake pads, visually inspect the caliper from below. The lining on the visible ends of the two brake pads should be at least 2 mm thick. Should the lining be thinner, immediately replace the brake pads. NOTE: Perform the check at the intervals specified in the Maintenance table in Chapter 3.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 11 Checking the level of the hydraulic clutch fluid To check the level of the fluid in the clutch pump, it is first necessary to remove cover 2. Remove the two screws 1 and take off cover 2 together with the rubber bellows. When the clutch pump is in a horizontal position, the fluid should be 4 mm below the upper rim. If necessary, top up with hydraulic fluid of the recommended type (see Chapter 3).
04_Inghilterra_059311 27-12-2007 18:10 Pagina 12 CONTROLS 1 Clutch lever Clutch lever 1 is fitted to the left-hand side of the handlebars. Screw A can be used to alter the home position of the lever (see Adjustments). 6 A Front brake lever Front brake lever 2 is fitted to the righthand side of the handlebars. Screw B can be used to adjust the home position of the lever (see Adjustments).
04_Inghilterra_059311 27-12-2007 18:10 Pagina 13 CONTROLS (RR4t USA) Starter button Starte button 3 is located on the right-hand side of the handlebars and operate the electri engine starter. Push the button until the engine sterts. Do not press the button 3 while the engine is running. LH switch Switch 11 is used to stop the engine. Press the button until the engine stops. While button 12 turns on the lights.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 14 Fork oil B Left/right fork leg To renew the oil, follow these steps: – Unscrew the four screws B fastening handlebar clamp C and remove the handlebars. C – Loosen leg clamping screws D and E. D E – Remove lower plug F and upper plug A (pay attention to the spring). – Allow the oil to drain completely from the fork leg. – Screw on lower plug F again. F – Pour in fresh oil of the type specified in the table in Chapter 3.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 15 Air filter A dirty air filter blocks the passage of air, reduces engine power and increases fuel consumption. For these reasons, it is essential to maintain the oil filter on a regular basis. 1 To gain access to the filter, follow these steps: – Remove the saddle. – Lift and rotate battery 1. – Release filter fastener 2. – Pull out air filter 3. – Carefully wash the filter in soap and cold water or using a suitable detergent. – Dry the filter.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 16 Spark plug Maintaining the spark plug in good condition makes for reduced fuel consumption and optimum engine performance. It is preferable to remove the spark plug when the engine is hot (obviously after switching it off) as the carbon formation and the colour of the insulator provide important information on carburation, lubrication and the general condition of the engine.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 17 Carburettor - Idle speed adjustment The adjustment of the idle speed strongly affects engine starting, i.e. an engine whose idle speed is properly adjusted is easier to start than an improperly tuned engine. The idle speed is adjusted by means of adjusting roller 1 and mixture adjusting screw 2.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 18 Emptying the float chamber Should the float chamber need to be emptied, use the following procedure when the engine is cold. Close the fuel cock and place pipe 4 in a container to collect the fuel that will flow out. Open drain screw 5 and drain the fuel. Close the drain screw again, open the fuel cock and check the seal of the system. 5 4 WARNING: Fuel is toxic and highly flammable. Handle it with the utmost care.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 19 Chain maintenance The life of the chain mainly depends on its maintenance. Chain without X-rings should be regularly cleaned in petroleum and then immersed in hot chain oil or treated with chain spray. The maintenance of X-ring chains is reduced to a minimum. The best way to clean them is to use plenty of water. Never attempt to clean an X-ring chain with brushes or solvents. Once the chain has dried, it is possible to use a spray for Xring chains.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 20 SUSPENSIONS Fork Adjusting the rebound damping The hydraulic rebound damping unit determines the behaviour of the fork during the rebound phase and is adjusted by means of screw A. Turning the screw clockwise (towards the + sign) or anticlockwise (towards the – sign) respectively increases or decreases the rebound damping.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 21 Adjusting the spring preload Use the following procedure to adjust the spring preload. Loosen locknut 1, turn ring nut 2 clockwise to increase the spring preload (and consequently the shock absorber preload) and anticlockwise to decrease it. Once the desired preload has been obtained, turn locknut 1 until it comes into contact with adjusting ring nut 2.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 22 DIGITAL RPM INDICATOR (RR4T Euro 3 version) SCROLL PUSHBUTTON The instrument panel has a pushbutton A which changes and sets the main functions. WARNING LIGHTS The instrument panel has three warning lights. Warning light B, GREEN, indicates turn indicators have been activated. Warning light C, BLUE, indicates when the high-beam light is ON.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 23 INSTRUMENT PANEL OPERATION Every time the battery is connected, the instrument panel checks all the functions. Once the CHECK phase is complete (around 2 seconds), the last preset operation is displayed. Every time the vehicle is turned off, the instrument panel stops showing the current information.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 24 CONVERSION PROCEDURE Km/h - Mph and wheel selection In order to convert km/h to mph, proceed as follows: - Set the instrument panel on the 1st screen, turn off the vehicle and press the SCROLL pushbutton. - Start the vehicle keeping the SCROLL pushbutton pushed until the symbol "Km/h" is displayed. - "Km/h" and "Mph Miles" will be displayed alternately. Press the SCROLL key when the intended unit of measurement is displayed.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 25 DIGITAL SPEEDOMETER (RR4T USA RS4T USA version) A CYCLING THROUGH THE FUNCTIONS It is always possible to cycle through the different functions while the vehicle is stationary or in motion.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 26 AUTOMATIC TRIP FUNCTION (TD) T≥ 3” resets LAP and TD T<3” cycles through functions A This function is always accompanied by the TD caption. The information displayed represents the total distance covered by the vehicle in kilometres or miles (according to the selected unit). It is an automatic counter which is activated by the first pulse generated by the speed sensor.
04_Inghilterra_059311 27-12-2007 18:10 Pagina 27 CHANGING THE WHEEL CIRCUMFERENCE, UNIT AND NUMBER OF PULSES The wheel circumference, the unit and the number of wheel pulses can be altered only when the vehicle is stationary. Hold down the button while the TOD function is active until the only information displayed is the circumference and all the other segments are switched off.
04_Inghilterra_059311 28 27-12-2007 18:10 Pagina 28 Workshop manual RR 4T - 400 - 450 - 525
05_Inghilterra_059311 27-12-2007 18:14 Pagina 1 BODYWORK AND FITTINGS 5
05_Inghilterra_059311 27-12-2007 18:14 Pagina 2 CONTENTS Removing the plastics . . . . . . . . . . . . . Chap. 5 - 3 Removing the saddle . . . . . . . . . . . . . . Chap. 5 - 3 Removing the rear mudguard . . . . . . . . Chap. 5 - 3 Removing Removing Removing Removing the the the the front side panels . . . . . . rear side panels . . . . . . . right-hand side bumper left-hand side bumper . . Chap. Chap. Chap. Chap. 5 5 5 5 - 4 4 4 4 Removing the front mudguard . . . . . . . Chap.
05_Inghilterra_059311 27-12-2007 18:14 Pagina 3 Removing the plastics To make some areas of the vehicle easier to check and service, it is first necessary to remove parts of the bodywork as described below. A Removing the saddle Remove the two fixing screws A (one on each side), lift the saddle as shown in the figure and pull it back and off the vehicle. Removing the rear mudguard Remove the two fixing screws B and then the two screws C and D from under the rear mudguard.
05_Inghilterra_059311 27-12-2007 18:14 Pagina 4 Removing the front side panels Unscrew the eight fixing screws E (four on each side) and take off the front side panels. E Removing the rear side panels Unscrew the four fixing screws F (two on each side) and take off the rear side panels. In addition to fastening the rear side panel, the upper screw also fixes the saddle.
05_Inghilterra_059311 27-12-2007 18:14 Pagina 5 Removing the front mudguard Remove the four screws L from under the front mudguard. L Also remove mudguard brace fixing screw M from under the mudguard. M Finally remove the two brace fixing screws N from the top of the brace. M Removing the fork covers Unscrew the eight fixing screws P (five on the left side and three on the right side) and remove the fork covers.
05_Inghilterra_059311 27-12-2007 18:14 Pagina 6 Removing the headlight grille Release the two rubber bands Q as shown in the figure, pull out the headlight and remove grille R.
63_Inghilterra_059311 27-12-2007 18:17 Pagina 1 ENGINE SECTION - REMOVING THE ENGINE FROM THE VEHICLE - DISASSEMBLING THE ENGINE - OVERHAULING THE ENGINE - REASSEMBLING THE ENGINE - INSTALLING THE ENGINE ON THE VEHICLE 6
63_Inghilterra_059311 2 27-12-2007 18:17 Pagina 2 Workshop manual RR 4T- 400 - 450 - 525
63_Inghilterra_059311 27-12-2007 18:17 Pagina 3 ENGINE SECTION - REMOVING THE ENGINE FROM THE VEHICLE 6
63_Inghilterra_059311 27-12-2007 18:17 Pagina 4 CONTENTS Removing the saddle . . . . . . . . . . . . . . . Chap. 6 - 5 Removing the fuel tank . . . . . . . . . . . . . Chap. 6 - 5 Removing the right-hand side panel . . Chap. 6 - 6 Removing the silencer . . . . . . . . . . . . . Chap. 6 - 6 Draining the cooling system . . . . . . . . . . Chap. 6 - 6 Removing the left-hand radiator . . . . . . Chap. 6 - 7 Removing the horn . . . . . . . . . . . . . . . . . Chap.
63_Inghilterra_059311 27-12-2007 18:17 Pagina 5 Place the vehicle on a central stand. Drain the engine oil (see Chapter 4 Maintenance). Removing the saddle Remove the left-hand and right-hand saddle screws. Remove the saddle by pulling it towards the back of the vehicle. Removing the fuel tank To remove the tank together with the deflectors, unscrew the left-hand and right-hand screws fixing it to the radiator. Remove the central screw as shown in the figure and disengage the tank.
63_Inghilterra_059311 27-12-2007 18:17 Pagina 6 Removing the right-hand side panel To gain access to the silencer fixing screws, it is first necessary to remove the right-hand side panel. Pay attention to the plastic catches between the side panel and the mudguard. Removing the silencer Loosen the two screws shown in the figure. Remove the spring that fastens the silencer to the exhaust pipe. Be careful to avoid injury from the spring.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 7 Removing the left-hand radiator To remove the left-hand radiator, it is first necessary to disconnect the upper pipe after removing the clamp as shown in the figure. Subsequently remove the clamp as shown in the figure and remove the lower pipe. Removing the horn Remove the horn and the related bracket so as to facilitate the removal of the plastic bumper. Loosen the two screws 1 and remove the left-hand radiator.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 8 Removing the intake sleeve Disconnect the carburettor intake sleeve. Rear frame Remove the two screws 1 to the left and right of the rear frame and loosen the two screws 2. 2 1 Disconnecting the electrical system Disconnect all the electrical connections, cutting the wire clamps where necessary. Tipping over the rear frame It is now possible to overturn the rear frame towards the front of the vehicle.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 9 Disengaging the exhaust pipe Release the two springs that support the exhaust pipe with the cylinder Take care to avoid hand injury. Remove the screw that fixes the exhaust pipe to the frame. Releasing the rear shock absorber Disengage the shock absorber from the frame as shown in the figure. Removing the exhaust pipe It is now possible to remove the exhaust pipe by pulling it towards the front of the vehicle.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 10 Removing the engine/swingarm pin Remove the engine/swingarm pin. For safety reasons, it is advisable to unscrew the left side while holding the pin in position on the right side. Removing the rear suspension linkage Remove the linkage pin as previously described. Removing the rear end The swingarm assembly can now be removed from the vehicle.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 11 Removing the brake pedal pull-off spring Removing the spark plug cap Removing the water delivery pipe from the pump Removing the front sprocket casing Unscrew screw 1 and screw 2 on the opposite side. 1 2 Removing the clutch pump assembly Remove the clutch assembly without disconnecting the pipe so as to avoid having to fill and bleed the system again.
63_Inghilterra_059311 27-12-2007 18:18 Pagina 12 Releasing the decompressor cable Removing the engine Remove the lower engine/frame pivot pin. Remove the upper engine/frame pivot pin. Removing the kickstart Loosen the screw shown in the figure and remove the kickstart. Removing the engine from the frame Remove the engine from the frame, extracting it from the left side. Place the engine on special tool 3625132.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 13 6 ENGINE SECTION - DISASSEMBLING THE ENGINE Pag.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 14 CONTENTS Draining the oil . . . . . . . . . . . . . . . . . . Chap. 6 - 15 Removing the oil filters . . . . . . . . . . . . Chap. 6 - 15 Removing the front sprocket . . . . . . . Chap. 6 - 15 Removing the clutch . . . . . . . . . . . . . . Chap. 6 - 16 Pulling out the flywheel . . . . . . . . . . . Chap. 6 - 17 Removing the clutch hub and drum . . Chap. 6 - 17 Removing the oil pump . . . . . . . . . . . . Chap. 6 - 18 Removing the cylinder head top . . .
64_Inghilterra_059311 27-12-2007 18:22 Pagina 15 Draining the oil – Remove screws 1, 2 e 3 and drain the engine oil into a container. – Remove the kickstart and the gearchange lever. 2 NOTE: Dispose of spent oil without polluting the environment. 3 Should the engine oil come into contact with the skin, wash with plenty of soap and water. 1 Removing the oil filters – Unscrew the four screws and remove the two oil filter covers 4. 4 4 – Pull the two oil filters out of the crankcase.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 16 Removing the clutch – Unscrew all clutch cover screws and remove the cover with its gasket. – Remove the two centring bushes from the crankcase. – To prevent the clutch plates from jamming when the clutch springs are released, loosen the screws following a crosswise pattern. – Remove the pressure plate with the screws, spring bracket and clutch springs. – Remove thrust head 1. – Remove all the lined and steel plates from the clutch drum.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 17 – Position the special tool as shown in the figure, unscrew the primary torque gear flange nut and remove it. – Remove the special tool. THERE ARE FLANGE NUTS WITH LEFT-HAND AND RIGHT-HAND THREADS. THE FLANGE NUTS BEARING THE CAPTION “LEFT” HAVE A LEFT-HAND THREAD. THOSE WITH NO INSCRIPTION HAVE A RIGHTHAND THREAD. – Bring the crankshaft to the top dead centre. – Unscrew crankshaft fixing screw 1 and remove retaining ring 2.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 18 – Remove clutch drum 1 together with stepped washer 2 and the two half washers 3 from the driving shaft. 3 3 – Remove the two needle roller bearings 4 and the support washer. 2 1 3 4 Removing the oil pump – Unscrew the two screws 5 and remove the oil pump cover. 4 – Remove roller 6, inner rotor 7 and outer rotor 8 from the oil pump casing. 8 7 6 – Remove oilway screws 9 e 10 with the related seal rings and then remove the oil line.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 19 Removing the cylinder head top – Unscrew all six screws with the related seal rings and remove the two valve covers 1 with their gaskets. – Unscrew the spark plug. 1 – Unscrew the four screws and remove water pump cover 2 with the related gasket. 2 – Unscrew all screws 3 on the cylinder head top. 3 3 3 3 3 – Using a plastic mallet, carefully hit area A in an upward direction and remove the cylinder head top.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 20 – Position the timing chain separating tool and undo the chain (see figure). – ENSURE THAT THE EJECTED NAILS DO NOT FALL INTO THE ENGINE. – HOLD THE TIMING CHAIN IN POSITION SO THAT IT DOES NOT FALL DOWN TOWARDS THE CHAIN CASING. – REMOVE THE OPEN CHAIN LINK AND REPLACE IT WITH A NEW ONE. Any link of the timing chain can be opened. – To prevent the timing chain from falling down to the chain casing, insert a wire clamp into each chain end.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 21 – Remove the Seeger ring and push the piston pin out of the piston. Remove the piston. Removing the timing chain and gear – Loosen the two screws 1 and remove chain guard 2. – Remove the timing chain. 1 1 2 – Remove screws 3 and 4, pull the chain stretcher and the chain guide up and out of the crankcase. 3 4 – Remove Seeger ring 5. 5 – Fit the puller and remove the timing gear from the crankshaft.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 22 Removing the electric start and kickstart gears – Remove the two Seeger rings 1 and the thrust washers. Remove kickstart idler gear 2 and electric start idler gear 3 from their support pins. 1 2 3 1 – Remove the double gear and the needle roller cage from the support pin. Remove the support pin from the crankcase. – Carefully unscrew flange screw 4 while holding the kickstart spring in position. Decompress the kickstart spring and unfasten it.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 23 Removing the primary torque gear and the free wheel – Remove flange nut 1. NOTE: THERE ARE FLANGE NUTS WITH LEFT-HAND AND RIGHT-HAND THREADS. THE FLANGE NUTS BEARING THE CAPTION “LEFT” HAVE A LEFT-HAND THREAD. THOSE WITH NO INSCRIPTION HAVE A RIGHT-HAND THREAD. – Pull out from the crankcase the oil pump shaft complete with the roller, inner rotor 3 and outer rotor 4. 1 2 3 4 – Remove the two opposed screws 5.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 24 Removing the gearshift mechanism and the gear shafts – Lay down the engine on one side. – Release the engine fastening on the stand. – Detach the left-hand crankcase half using suitable tools positioned on the specially designed supports. Alternatively, gently tap the driven shaft with a plastic mallet. TO PREVENT DAMAGE TO THE SEALING SURFACES, AVOID SEPARATING THE CRANKCASE WITH A SCREWDRIVER OR A SIMILAR TOOL.
64_Inghilterra_059311 27-12-2007 18:22 Pagina 25 Removing the countershaft and the crankshaft – Turn the crankshaft until the marks on the countershaft and the crankshaft are aligned. – In this position the crankshaft can be removed from its seat. – Remove the crankshaft. – Clean all the parts, check them for wear and replace as necessary. NOTE: When the engine is overhauled, it is advisable to replace all gaskets, oil seals, O-rings and bearings.
64_Inghilterra_059311 26 27-12-2007 18:22 Pagina 26 Workshop manual RR 4T - 400 - 450 - 525
65_Inghilterra_059311 27-12-2007 18:28 Pagina 27 6 ENGINE SECTION - OVERHAULING THE ENGINE Pag.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 28 CONTENTS IMPORTANT NOTE ABOUT CRANKCASE SERVICING . . . . . . . . . Chap. 6 - 29 Left-hand crankcase half . . . . . . . . . . Chap. 6 - 30 Right-hand crankcase half . . . . . . . . . Chap. 6 - 31 Desmodromic mechanism ball bearing 3 Chap. 6 - 32 “60” oil jet 8 . . . . . . . . . . . . . . . . . . . . Chap. 6 - 32 “100” oil jet 1 . . . . . . By-pass valve . . . . . Clutch cover . . . . . . Crankshaft oil seal 4 Oil channel 5 . . . . . . . . . . . . . .
65_Inghilterra_059311 27-12-2007 18:28 Pagina 29 IMPORTANT NOTE ABOUT CRANKCASE SERVICING NOTE: Read through this paragraph before beginning work, then determine the reassembly sequence so that the crankcase halves can undergo a single heat treatment for the replacement of the bearings. If necessary, use drifts of suitable diameter to remove the bearings. Remove the reference bushings and place the crankcase halves on a flat surface.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 30 Left-hand crankcase half Remove all the oil seals and heat the crankcase half in an oven at a temperature of approximately 150° C. 6 3 2 Crankshaft roller bearing 1 Using a suitable drift, push in the bearing from the outside. Fit the new bearing, pushing it from the inside to its abutting end. 8 Driving shaft ball bearing 2 Using a suitable drift, push in the bearing from the outside.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 31 The oil pump casing should show no signs of scoring or seizure. Blow all the oil channels with compressed air and ensure that they are clear. Check that the two steady pins 1 are firmly seated. If necessary lock with Loctite 243. Right-hand crankcase half Remove all the oil seals and heat the crankcase half in an oven to a temperature of approximately 150° C. Crankshaft roller bearing 2 Using a suitable drift, push in the bearing from the outside.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 32 Countershaft ball bearing 1 and oil seal 2 Using a suitable puller, extract the ball bearing from the crankcase half and remove the oil seal. Press in the new oil seal with the open side facing downwards until it is flush. Press in the new ball bearing to its abutting end. 1 2 Desmodromic mechanism ball bearing 3 Remove screw A. At a temperature of approximately 150° C the ball bearing comes out of its seat almost spontaneously.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 33 “100” oil jet 1 Remove the oil jet and blow the oil channel with compressed air. Degrease the oil jet thread, apply Loctite 243 and refit the oil jet. NOTE: : This jet provides the right quantity of oil for the connecting rod bearing. 1 By-pass valve Check that the valve piston, the sealing surface and the compression spring are not damaged. 2 Minimum length of compression spring 2: 23.5 mm If the spring is shorter than 23.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 34 A B Crankshaft If the connecting rod bearing is replaced, take care to properly position the coupling shaft. The holes in the shaft section A and in the coupling shaft B must be aligned. IF THE COUPLING SHAFT IS FORCED IN OUT OF POSITION, THE CONNECTING ROD BEARING WILL RECEIVE LITTLE OR NO OIL AND WILL CONSEQUENTLY BE DAMAGED. If the crankshaft is to be reused, be sure to check the offset of the shaft sections.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 35 Measuring the outside diameter of the handwheels Using a vernier caliper, measure the outside diameter of the handwheels as shown in the figure. Outside diameter of handwheels = 65 mm ± 0.05 mm Countershaft gear – To remove the countershaft gear from the crankshaft, it is first necessary to remove the inner ring nut of the cylindrical roller bearing (see below).
65_Inghilterra_059311 27-12-2007 18:28 Pagina 36 Cylinder - Nikasil lining Nikasil is the trademark of a cylinder lining procedure developed by the piston manufacturer Mahle. The name is derived from the two materials used in the procedure – nickel containing silicon carbide to make a particularly hard substance. The principal advantages of Nikasil are excellent heat dissipation, making for an increased power supply, and reduced cylinder weight and wear.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 37 Checking the piston – Replace the piston if oil consumption is excessive or if the piston skirt is scored. – If the piston is to be reused: 1.Check the wear of the piston sliding surface. 2.Check that the piston rings can move freely in their grooves. Clean the grooves with an old piston ring or with emery paper (400 grain). 3.Check the piston ring wear and gaps (see below). 4.When installed, the piston pin should float in its hole.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 38 2 2 5 1 7 3 8 4 6 7 7 7 6 8 7 7 3 Lubrication system Oil line 1 Ensure that the soldered joints present no capillary cracks. Blow the oil line with compressed air to check whether the passage is clear. Also check that there are no friction points on the oil line. Always replace the seal rings with new ones (8x12x1). O-ring 2 At each oil change, also replace the O-rings.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 39 10 4 10 6 4 5 2 11 3 1 7 7 9 9 8 Cylinder head top – Remove Seeger ring 1 and pull decompressor shaft 2 and spring 3 out of the hole. – Remove the two terminals 4 from the cylinder head top together with rocker arm pivots 5 and 6. Remove rocker arms 7. – Clean all the components and check them for wear. Rocker arm pins 5 and 6 The rocker arm pivots should show no signs of scoring and should rotate freely in rocker arms 7.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 40 modelli 250 modelli 250 2 1 Cylinder head – Unscrew the three screws 1 and remove exhaust flange 2 together with its gasket. – Using the specially designed tool, remove the four valves. – The 250 cc model fits conical valves. – Used valves are to be reinserted in the same valve guide. To ensure this, we recommend inserting the valves in a piece of cardboard in the same way they are fitted in the cylinder head (see figure).
65_Inghilterra_059311 27-12-2007 18:28 Pagina 41 – Remove spring caps 1 and valve springs 2 from the cylinder head. – Remove the valve stem linings from the valve guides and remove spring holders 3. The 250 cc model fits conical springs. Sealing surface Check the spark thread and the valve seats for damage or cracks. Using a straightedge and a thickness gauge, check to see if any distortion is present. Maximum allowable distortion: 0.10 mm.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 42 12 10 11 8 6 5 9 7 4 8 2 3 1 Camshaft – Remove Seeger ring 1 and water pump impeller 2. – Pull out roller 3 from the shaft hole and remove lining holder 4 from the camshaft. – Remove ball bearing 5 from the camshaft with a suitable puller (see figure). NEVER CLAMP THE CAMSHAFT IN A VICE. – Release spring 6 from decompressor shaft 7 while extracting the latter from the camshaft. – Unscrew the two screws 8 and remove camshaft gear 9.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 43 – Press oil seals 1 out of seal holding bush 2. – Fit the new oil seals with the gaps facing outward, pressing them in until they are flush. Carefully grease the sealing lips. – Remove the two O-rings 3 from the seal holding bush and remove any residues with a wire brush. – Fit two new O-rings. – The seal holder can be removed from the cylinder head with the aid of the two M3 threaded holes 4 without removing the cylinder head top.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 44 Automatic stretcher – Fully extract the automatic stretcher pressure pin and check that it can slide freely. – Check the wear of the pressure pin teeth and the dog. ➙ ➙ – When refitting, push the dog in the direction indicated by the arrow so that the pressure pin no longer jams and then fully insert the pressure pin into the stretcher body. ➦ Valve gear control Thoroughly clean all the components and check them for wear.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 45 Checking the clutch for wear Thrust head 1 Check the thrust head for signs of seizure and ensure that it can slide freely. Axial bearing 2 Ensure that the bearing is not damaged. Push rod 3 Place the push rod on a flat surface and check its offset. Clutch springs 4 Minimum length 41.5 mm (43 mm when new). If necessary, replace all six springs. Clutch hub 8 Check for damage and signs of wear.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 46 3 11 10 12 9 8 1 7 2 6 5 4 Checking the kickstart for wear Remove all components from the kickstart shaft and clean them. Starter gear 1 Check the wear of the teeth and the play of the support. Starter idler gear 2 Check to see if there is any play or any sign of seizure on the support. Check the wear of the teeth, which are in constant mesh with the clutch drum. Starter coupling 3 Check the inclined surface and the teeth for signs of wear.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 47 Gearshift mechanism Gearshift forks 1 Check wear at ends A. When the forks are new, their thickness ranges from 4.8 to 4.9 mm. The wear limit is 4.6 mm. Desmodromic mechanism 2 Check the wear of profiled grooves B. Check the desmodromic mechanism support in ball bearing 3. Ball bearing 3 Check that it can turn smoothly. Bushes 4 Ensure that the bushes present no dents or cracks. Fork guide rods 5 Check the offset of the rods on a flat surface.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 48 1 2 3 4 5 6 7 8 9 10 11 Gearbox Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove the gears and check if the following parts show signs of wear or seizure: • Needle roller cages. • Bearing surfaces of the driving shaft, driven shaft and idler gears. • Gear couplings. • Sides of all gear teeth. • Tooth profile of the driving and driven shafts and of the related gears.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 49 17 18 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 1 Gearbox Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove the gears and check if the following parts show signs of wear or seizure: • Needle roller cages. • Bearing surfaces of the driving shaft, driven shaft and idler gears. • Gear couplings. • Sides of all gear teeth. • Tooth profile of the driving and driven shafts and of the related gears.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 50 Ignition system General information The measurements described below are only used to find easily detectable faults. Inside short circuits, which produce feeble sparks with a low ignition power, can only be discovered with a specially designed ignition test bench. In case of problems first check the wires and connectors of the ignition system. When taking a measurement, be sure to use a suitable measuring range.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 51 7 6 1 2 3 5 A 4 Electric start gears Idler gear 1 Check the teeth and the bearing surface of the idler gear for signs of wear. Also check the idler gear support pin for signs of seizure. Double gear 2 Check the teeth and the bearing surface of the double gear for signs of wear. Also check the double gear support pin for signs of seizure. Fit the double gear together with the needle roller cage on the support pin and check the play.
65_Inghilterra_059311 27-12-2007 18:28 Pagina 52 Checking the operation of the free wheel – Fit free wheel gear 1 on free wheel device 2. – The free wheel gear should rotate clockwise. – Attempting to rotate the free wheel gear anticlockwise should lock the gear with no idle travel. 1 2 Replacing the free wheel hub – Squeeze expansion ring 3 with a pair of Seeger pliers and remove it together with free wheel 2. 3 2 – Remove the six screws 4.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 53 ENGINE SECTION - REASSEMBLING THE ENGINE 6
66_Inghilterra_059311 27-12-2007 18:32 Pagina 54 CONTENTS Fitting the crankshaft and the countershaft . . . . . . . . . . . Chap. 6 - 55 Fitting the gearbox and the gearshift mechanism . . . . . Chap. 6 - 55 Assembling the crankcase . . . . . . . . . Chap. 6 - 57 Fitting the oil pumps . . . . . . . . . . . . . . Chap. 6 - 58 Fitting the gear selector . . . . . . . . . . . . Chap. 6 - 59 Fitting the electric start and kickstart gears . . . . . . . . . . . . Chap. 6 - 59 Fitting the clutch drum and hub .
66_Inghilterra_059311 27-12-2007 18:32 Pagina 55 Fitting the crankshaft and the countershaft – Fasten the right-hand crankcase half to the assembly stand. – Carefully oil the crankshaft roller bearing and grease the oil seal. – Carefully insert the crankshaft into the bearing. – Turn the crankshaft until mark A is at the front and then insert the countershaft into its bearing. Ensure that crankshaft mark A is between the two countershaft marks B.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 56 – Oil the ends of the gearshift forks and attach them to the sliding gears. 1 – Insert the desmodromic mechanism into its bearing. A – Attach the gearshift forks to the desmodromic mechanism and fit the two fork guide rods 2 along with the springs.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 57 30 M6x... 30 45 45 60 45 75 60 45 45 NOTE: This diagram shows all the lengths of the carter fixing screws. 45 Assembling the crankcase – Remove the engine retainer from the stand. – Apply a thin film of grease to the crankcase sealing surface and fit a new gasket. – Lay down the left-hand crankcase half and tap it with a plastic mallet until it is properly positioned. – Ensure that the crankcase gasket is properly seated.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 58 Fitting the oil pumps – Using a cloth, carefully clean the rest surface of the oil pump cover. – Insert the roller into the oil pump shaft. – Fit the inner and outer rotors to the oil pump shaft so that the two centres A and B are placed next to each other, and then insert all the part into the crankcase. A The inner and outer rotors should be fitted so that their centres face the crankcase. – Fill the oil pump casing with engine oil.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 59 Fitting the gear selector – Fit screw 1 (M5x20) with washer 2, selector lever 3, spring holding bush 4 and selector lever spring 5. – Apply Loctite 243 to the screw thread and tighten the screw to 6 N·m. 1 3 2 1 4 5 – Move the selector lever away from the desmodromic mechanism and fit the latter with the gear selector. Ensure that the flat points are off-centre. – Apply Loctite 243 to the thread of the screw 7 (M6x30) and tighten to 10 N·m.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 60 – Insert the support pins into the crankcase holes. Fit needle roller cage 1 and double gear 2. 1 2 – Insert the preassembled kickstart shaft into the bearing hole so that the starter coupling is located behind the release plate.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 61 Fitting the clutch drum and hub – Insert the support washer and needle roller bearings 1. – Fit the driving shaft with clutch drum 2, half washers 3 and stepped washer 4. 2 3 4 1 – Heat the clutch hub to approx. 150° C and key it on the driving shaft. – Fit a new safety plate. – Degrease the driving shaft thread and apply Loctite 243 to it. – Position the special tool (see removal procedure), fit flange nut 5 and tighten it to 150 N·m.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 62 Fitting the timing gear – Ensure that the key is properly seated in the crankshaft. – Heat timing pinion 1 and fit it to the crankshaft with the high end facing inward. If necessary, gently tap with a suitable tube. – Fit Seeger ring 2 with the sharp edge facing outward. 1 2 – Degrease the threads of the two screws (M6x25) and apply Loctite 243.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 63 Fitting the piston and the cylinder – Fit a new cylinder base gasket. – Oil the piston pin bearing in the connecting rod and the piston pin itself. – Fit the piston and fasten the piston pin with two new retaining rings. NOTE: THE ARROW ON THE PISTON TOP MUST POINT IN THE DIRECTION OF TRAVEL. - Oil the piston and fit the piston rings. The scraper ring gap should face the back of the vehicle.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 64 Ensure that drain hole A is facing upwards. A – Insert the camshaft in the cylinder head so that marks B on the camshaft gear are aligned with the upper edge of the cylinder (see figure). The automatic decompressor stop screw must be positioned at the top. Before fitting the camshaft, lock the crankshaft at the top dead centre using the crankshaft fixing screw. – Fit the timing chain on the camshaft gear and then fit a new chain joint 1.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 65 Fitting the cylinder head top – Clean or degrease the sealing surfaces of the cylinder head top and the cylinder head itself. – Insert the centring bushes in the cylinder head. – Apply a thin film of sealant (Three Bond) over the cylinder head sealing surface. – Carefully position the cylinder head top and tighten the screws to 10 N·m. For the screw lengths, refer to the diagram. NOTE: – Fit the M6x75 screw with a new copper ring 6x10x1. M6x...
66_Inghilterra_059311 27-12-2007 18:32 Pagina 66 Fitting the automatic stretcher – Fit the preassembled automatic stretcher 1 with a new gasket. – Fit the two screws (M6x20) with the 6x10x1 copper rings and tighten them to 8 N·m. 1 – Using a screwdriver, push in the pressure pin until a slight resistance is felt, then push it in one further notch. – Fit the compression spring and the clamp screw with a new retaining ring and then tighten to 10 N·m.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 67 Fitting the flywheel – Unscrew the crankshaft fixing screw, fit seal ring 1 and tighten the crankshaft fixing screw to 25 N·m (see above). – Ensure that the key is properly seated in the crankshaft and then fit the flywheel on the crankshaft. – Fit the wave washer and the flange nut. Pushing with the clutch retainer, tighten the flange nut to 60 N·m.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 68 Fitting the clutch – Before fitting the clutch, carefully oil the lined plates. Clutch plates – Place the twelve dragging bushes 3 in the hub. If necessary fix them with a little grease. – Starting with a middle plate 6 and 6A, alternate eight middle plates with seven lined plates 5, ending with a thin middle plate 6 at the top. (see figure to side) – Fit the thrust head.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 69 Fitting the oil line - Position oil line 3 and fasten it with the two oilway screws 1 and 2, using new seal rings. Tightening torque: 10 N·m. 1 2 Position the oil line so that it does not come into contact with the engine. Also, when tightening, ensure that the oil line is not taut. 3 Installing the starter motor – Carefully oil the O-ring on the starter motor and insert the motor in the crankcase.
66_Inghilterra_059311 27-12-2007 18:32 Pagina 70 Fitting the oil filter – Pour engine oil into the oil filter casings until they are about 1/4 full. – Insert the two oil filters 1 in the crankcase. 1 – Oil the O-rings on the oil filter covers and fix covers 2 with the four screws (M5x16), applying a tightening torque of 6 N·m. – Fit the kickstart and the gearshift lever. 2 Adding engine oil – Fit clamping screws 3 and 4 and oil drain screw 5 and then tighten them.
67_Inghilterra_059311 27-12-2007 18:38 Pagina 71 ENGINE SECTION - INSTALLING THE ENGINE ON THE VEHICLE 6
67_Inghilterra_059311 27-12-2007 18:38 Pagina 72 To mount the engine on the vehicle, follow the procedures described for its removal in reverse order, taking care to apply the tightening torques and use the products specified in Chapter 3 Tightening torques - Specifications Recommended products.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 1 CARBURETTOR 7
07_Inghilterra_059311 27-12-2007 18:44 Pagina 2 CONTENTS CARBURETTOR - KEIHIN FCR M X 39 . . . Chap. 7 - 3 Removing and reinstallin the carburettor . . . . . . . . . . . . . . . . Chap. 7 - 4 Disassembling the carburettor . . . . . . Chap. 7 - 5 Choke valves . . . . . . . . . . . . . . . . Checking the accelerating pump Checking the jet needle . . . . . . . Checking the float needle valve . Checking the throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. Chap. Chap.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 3 CARBURETTOR - KEIHIN FCR M X 39 7 - Carburettor Release 01 Date 09/2007 3
07_Inghilterra_059311 27-12-2007 18:44 Pagina 4 Removing and reinstalling the carburettor NOTE: Before starting work on the carburettor, thoroughly clean the vehicle. – Remove the saddle and the fuel tank with the deflectors. – Unscrew the throttle twist grip. – Loosen the clamp screw on the float chamber, drain the fuel into a suitable container, then tighten the screw again. – Unplug the valve sensor connector. – Disconnect the sleeve. – Remove the carburettor from the frame top.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 5 Disassembling the carburettor NOTE: The disassembly should be carried out in a clean workplace with sufficient space to properly arrange all carburettor components. – Remove the carburettor and clean it of coarse dirt. – Loosen the two screws 1 and remove all breather pipes from the carburettor. 1 1 – Remove the two screws 2 and remove the throttle valve cover from the carburettor with the related gasket.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 6 – Rotate the carburettor, loosen the three screws and remove the accelerating pump cover. NOTE: When removing the cover, ensure that the spring and the seal rings are not lost. – Remove the two seal rings, the spring and the diaphragm from the pump casing. – Remove the float chamber screws and detach the float chamber. – Remove float pin 1 and remove the float together with the needle valve. – Remove main jet 2.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 7 – Remove screws 1 and throttle sensor 2. 1 Remove the throttle sensor only if it is defective. The throttle speed sensor needs to be readjusted every time screws 1 are loosened. 2 – Remove screw 3 and pull the connecting piece out of the carburettor. 3 – Loosen the two screws and remove the suction pump and Oring 4 from the carburettor. – Unscrew choke idling jet 5 and choke main jet 6.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 8 Choke valves Ensure that choke knob piston 1 presents no deep scoring or residues. 1 Checking the accelerating pump Check that the diaphragm is not cracked or porous. Check that the gaskets are not damaged. Ensure that holes 2 are clear. 2 2 Checking the jet needle Ensure that the jet needle is not bent or worn. Checking the float needle valve Check to see if the sealing surface of the needle valve presents any dimples.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 9 Reassembling the carburettor – Fit choke idling jet 1 and choke main jet 2. – Fit O-ring 3 in the groove and fasten the suction pump to the carburettor with the two screws. 3 1 2 – Insert the fuel connection into the carburettor and fasten it with screw 4. NOTE: When fitted, the connection should turn easily and smoothly. 4 – Fit choke knob 5 and operate it a few times to make sure it slides properly. Also check if the knob engages properly.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 10 – Position the float and the needle valve and fit float pin 1. – Check the float level (see page 14). 1 – Fit the carburettor float chamber complete with its gasket, position adjusting screw support 2 and fasten the float chamber by means of screws 3. 2 When fitting the carburettor float chamber, ensure that accelerating pump push rod 4 slides into the hole.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 11 – Apply Loctite 243 to screw 1 and tighten it. – Fit the jet needle and fasten it with screw 2. 2 1 – Position the throttle valve cover with the related gasket and fasten it with the two screws 3. 3 3 – Fasten the breather pipes with the two float chamber screws 4.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 12 Checking the throttle sensor NOTE: The following measurement should be taken when the temperature of the part is approximately 20° C. – Unplug the throttle sensor. – Connect a multimeter (measuring range Ωx 1k) to the blue (+) and black (–) wires of the throttle sensor. THROTTLE SENSOR RESISTANCE: 4 – 6 kΩ – Now connect the multimeter to the yellow (+) and black (–) wires of the throttle sensor.
07_Inghilterra_059311 27-12-2007 18:44 Pagina 13 Carburettor - Idle speed adjustment The adjustment of the idle speed strongly affects engine starting. In other words, an engine whose idle speed is properly adjusted is easier to start than an improperly tuned engine. The idle speed is adjusted by means of adjusting roller 1 and mixture adjusting screw 2.
07_Inghilterra_059311 14 27-12-2007 18:44 Pagina 14 Workshop manual RR 4T - 400 - 450 - 525
08_Inghilterra_059311 27-12-2007 18:49 Pagina 1 8 FRONT SUSPENSION / WHEEL Pag.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 2 CONTENTS Fork components . . . . . . . . . . . . . . . . . Chap. 8 - 4 Taking down the wheel . . . . . . . . . . . . . Chap. 8 - 5 Checking the head tube seats . . . . . . . Chap. 8 - 6 Cleaning the wiper seal Removal . . . . . . . . . . Installation . . . . . . . . Air bleed screw . . . . . . . Removal . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
08_Inghilterra_059311 27-12-2007 8 - Front suspension / wheel 18:49 Pagina 3 Release 01 Date 09/2007 3
08_Inghilterra_059311 27-12-2007 18:49 Pagina 4 9 10 48 19 39 24 21 Fork components 5) Supporting tube 8) Lower sliding bush 9) Cup 10) Seal ring 12) Wiper seal 13) Outer leg holder 19) Compression adjusting screw 21) Spring 24) Spring guide 25) Preload tube 4 13 25 34 33 36 37 43 30 31 72 73 28) 30) 31) 32) 33) 34) 36) 37) 39) 41) 43) 12 33 28 32 Foot pad Cartridge case Inside rod Pump rod Fin pull-off spring Rebound piston fin Pump piston Rebound damping piston reeds Upper slidin
08_Inghilterra_059311 27-12-2007 18:49 Pagina 5 Taking down the wheel NOTE: Place the vehicle on a specially designed central stand and keep the front wheel off the ground. – Remove wheel holder cap 1. – Loosen the two screws 2 on the left-hand fork foot. 1 2 – – – – Remove the two screws 3 from the right-hand fork foot. Pull out the fork pin on the right side. Remove the wheel assembly.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 6 If necessary, follow these steps to overhaul the steering seats: – Unscrew the four screws as shown in the figure and remove the handlebars. – Unscrew screws 1 and 2 and remove the two brackets from the head tube. 1 2 Checking the head tube seats Check the seats for wear. If necessary, remove them using a suitable drift. – For each seat, use a drift and a hammer to alternately hit the grooves in the head tube to the left and right of the seat.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 7 Cleaning the wiper seal NOTE: This operation can be performed with the fork installed on the vehicle. 13 Removal – Before performing this operation, thoroughly clean leg 6. – Using a small screwdriver, pry dust scraper 12 off sheath 13 taking care not to score the fork leg. – Push down the wiper seal along the leg and, using a jet of compressed air, clean the wiper seal inside and its seat on the sheath.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 8 Draining the oil NOTE: This operation cannot be performed while the fork is installed on the vehicle. 48 NOTE: It is advisable to slightly loosen the plug before removing the fork leg from the steering plates. – Remove the fork leg from the steering plates as directed by the manufacturer. – Clamp the fork leg in a vice. – Using a 19-mm spanner, completely unscrew plug 48. – Slowly lower the sheath along the fork leg.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 9 Removing the pump assembly and the foot valve Perform this operation only after completely draining the oil from the fork leg. – Clamp the wheel holding foot of the fork leg in a vice. – Stop the rotation of the case by accurately inserting the hexagon on the case into the slotted hole at the lower end of the tool. In the upper part of the tool there are two diametrically opposite holes where a pin can be inserted to facilitate its locking.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 10 – Push rod 32 towards the inside of case 30 to allow the pump assembly to be removed from below. 30 NOTE: The pump can be completely overhauled and adjusted. – Check ring 35 for wear. 32 35 Separating the fork leg from the leg holder and removing the seal rings – Using a small flat blade screwdriver, remove wiper seal 12. – Using the same screwdriver, remove metal retaining ring 11.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 11 – Remove fork leg 6 from sheath 13. Pull hard to obtain the separation. This operation will remove from the sheath seal ring 10, cup 9 and lower guide bush 8. – Manually remove upper guide bush 39. If the bush is difficult to remove by hand, the operation can be facilitated by inserting a flat blade screwdriver in the bush slot. – Remove lower guide bush 8, cup 9, seal ring 10, retaining ring 11 and dust scraper 12 from the fork leg.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 12 Installation 35 NOTE: Fins 37 and piston 36 determine the rebound damping action. If necessary, the behaviour of the fork during the rebound phase can be altered by replacing fins 37 and piston 36 with other parts having different characteristics. 37 Only use genuine Betamotor fins and pistons. Do not modify the components. 36 – If necessary replace piston ring 35.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 13 Installation 33 NOTE: Fins 46 and piston 45 determine the compression damping. If necessary, the behaviour of the fork during the compression phase can be altered by replacing fins 46 and piston 45 with other parts having different characteristics. 44 43 45 46 Only use genuine Betamotor fins and pistons. Do not modify the components. – If necessary replace piston O-ring 44.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 14 – Remove the adhesive tape from the end of the fork leg, cleaning it of any traces of adhesive. – Manually insert upper guide bush 39. NOTE: If the guide bush is difficult to insert by hand, the operation can be facilitated by inserting a flat blade screwdriver in the bush slot. 39 – Gently insert the fork leg into the sheath, taking care to ensure that the upper guide bush does not receive damage.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 15 Reassembling the pump assembly and the foot valve – Insert pump rod 32 into case 30. 30 Each pump contains a seal ring. Before reassembly, check that the seal rings are not worn or damaged and if necessary replace them. Be very careful and if necessary use a small flat blade screwdriver to facilitate the insertion of the pump piston into the tube-case. The piston should go unimpeded.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 16 – Push preassembled pump 23 until it comes into contact with fork leg 5. – Manually screw in the foot valve. – Stop the rotation of the case by carefully inserting the hexagon on the case into the slotted hole at the lower end of the tool. 23 In the upper part of the tool there are two diametrically opposite holes where a pin can be inserted to facilitate its locking.
08_Inghilterra_059311 27-12-2007 18:49 Pagina 17 – Open the adjuster by completely unscrewing adjusting screw R. 48 – Using two 19-mm spanners, tighten counternut 23 on plug 48 to the prescribed torque (see table in Chapter 3 Tightening torques - Specifications - Recommended products). R 23 – Push up the sheath along the fork leg. – Using the 19-mm spanner, screw plug 48 on the leg holder to the prescribed torque (see table in Chapter 3 Tightening torques - Specifications - Recommended products).
08_Inghilterra_059311 18 27-12-2007 18:49 Pagina 18 Workshop manual RR 4T - 400 - 450 - 525
09_Inghilterra_059311 27-12-2007 18:53 Pagina 1 9 REAR SUSPENSION / WHEEL Pag.
09_Inghilterra_059311 27-12-2007 18:53 Pagina 2 CONTENTS Removing the chain . . . . . . . . Taking down the rear wheel . . Removing the rear sprocket . . Removing the rear brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. Chap. Chap. Chap. 9 9 9 9 - 4 4 4 4 Removing the swingarm . . . . . . . . . . . . Chap. 9 - 5 Removing the shock absorber . . . . . . . Chap.
09_Inghilterra_059311 27-12-2007 18:53 Pagina 3 Before attempting to remove the rear suspension, place the vehicle on a central stand with the rear wheel off the ground.
09_Inghilterra_059311 27-12-2007 18:53 Pagina 4 Removing the chain Find the split link and position it on the rear sprocket. Remove the link with a pair of pliers and undo the chain. When refitting, it is important that the link should be fitted in the opposite direction to the rotation of the chain (see figure). Taking down the rear wheel Loosen the chain stretchers on the left and right sides. Unscrew wheel spindle nut 1.
09_Inghilterra_059311 27-12-2007 18:53 Pagina 5 Verificare che l’errore massimo di planarità sui 360° non sia superiore a 0,04 mm. When refitting the parts, tighten them to the prescribed torques (see Chapter 3 Tightening torques - Specifications - Recommended products). Removing the swingarm Disengage the swingarm from the rear brake line and from the caliper with its support bracket. Unscrew the swingarm/frame pin and the swingarm/linkage pin. Remove the swingarm. .
09_Inghilterra_059311 6 27-12-2007 18:53 Pagina 6 Workshop manual RR 4T - 400 - 450 - 525
10_Inghilterra_059311 27-12-2007 18:56 Pagina 1 10 BRAKING SYSTEM Pag.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 2 CONTENTS Front brake pump Overhauling the front brake pump . Chap. 10 - 4 Replacing the front brake pads . . . . . . Chap. 10 - 5 Replacing the front brake caliper pistons . . . . . . . . . . . . . . . Chap. 10 - 5 Replacing the rear brake pump . . . . . . . Chap. 10 - 6 Replacing the rear brake pads . . . . . . . Chap. 10 - 7 Replacing the caliper pistons . . . . . . . Chap.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 3 Special attention should be given to the braking system. No special maintenance is required, but frequent checks and thorough inspections are necessary, especially if the vehicle is used in competitions. 10 - Braking system Release 01 Date 09/2007 Visually check all the components and in particular the pump, the pipes and the caliper. Ensure that there are no leakages and that all the components are in good condition.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 4 Front brake pump Overhauling the front brake pump – Empty the system. – Unscrew front brake lever screw 1. The replacement can only be performed after emptying the system. Avoid disposing of the fluid in the environment. Dispose in accordance with the law. 1 – Remove the pump and replace it with a new spare kit. Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.1 oil.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 5 Replacing the front brake pads To replace the brake pads, follow these steps: – Push the brake caliper towards the disc so that the pistons can reach their base position. – Loosen grub screw A. – Pull out pin B while supporting the two brake pads as shown in the figure. – Remove the pads taking care not to drop the leaf spring located underneath. – To refit the parts, follow the reverse procedure.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 6 Replacing the rear brake pump 1 The replacement can only be performed after emptying the system. Avoid disposing of the fluid in the environment. Dispose in accordance with the law. – Remove right-hand guard 1 (if present). – Unscrew nut 2 to disengage the brake lever pump. – Remove the pump from below and replace it with a new one from the spare kit. 2 Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.
10_Inghilterra_059311 27-12-2007 18:56 Pagina 7 Replacing the rear brake pads To replace the brake pads, follow these steps: – Push the brake caliper towards the disc so that the pistons can reach their base position. – Loosen grub screw A. – Pull out pin B while supporting the two pads (see figure). – Remove the pads taking care not to drop the leaf spring above them. – To refit the parts, follow the reverse procedure. When fitting the brake pads, ensure that the leaf spring is properly positioned.
10_Inghilterra_059311 8 27-12-2007 18:56 Pagina 8 Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311 27-12-2007 18:59 Pagina 1 11 ELECTRICAL SYSTEM Pag.
18:59 Pagina 2 21 27-12-2007 23 25 20 29 35 2 14 13 12 11 10 9 8 7 6 5 4 3 2 1 15 38 16 36 37 17 34 27 26 18 32 33 28 30 19 31 24 22 11_Inghilterra_059311 Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311 27-12-2007 18:59 Pagina 3 WIRING DIAGRAM Euro 3 1) RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB) 2) FRONT BRAKE LIGHT BUTTON 3) START BUTTON 4) WHEEL REVOLUTION SENSOR 5) SCROLL BUTTON 6) TELL TALE LAMP (NO CONECT) 7) HEADLIGHT TELL TALE LAMP 8) TRAFFICATOR LIGHTS TELL TALE LAMP 9) DISPLAY 10) ENGINE STOP BUTTON 11) HORN BUTTON 12) HEADLIGHT SELECTOR 13) TURN SIGNAL LAMPS SWITCH 14) L.H.
11_Inghilterra_059311 4 27-12-2007 18:59 Pagina 4 Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311 27-12-2007 18:59 Pagina 5 WIRING DIAGRAM RR4T USA 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) WHEEL SENSOR STARTING BUTTON PUSHBUTTON SCROLL NO CONNECT TELL TALE LAMP NO CONNECT TELL TALE LAMP NO CONNECT TELL TALE LAMP DISPLAY ENGINE STOP BUTTON LIGHTS SWICH CONTROL GROUP REGULATOR ELECTROVALVE KIT (OPTIONAL) TAIL LAMP (LED) FUSE 10 A EARTH BRAID POSITIVE BATTERY STARTER RELAY STARTER MOTOR NEGATIVE BATTERY BATTERY 12V-4AH PIC
11_Inghilterra_059311 6 27-12-2007 18:59 Pagina 6 Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311 27-12-2007 18:59 Pagina 7 WIRING DIAGRAM RS4T USA 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 37) 38) 39) 40) RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB) FRONT BRAKE LIGHT BUTTON START BUTTON WHEEL REVOLUTION SENSOR HIGH BEAM WARNING LIGHT TURN INDICATOR WARNING LIGHT DISPLAY LOW BEAM WARNING LIGHT NOT CONNECTED MODE BUTTON ENGINE STOP BUTTON HORN BUTTON LIGHTS SELECTOR SWITCH TURN INDICA
11_Inghilterra_059311 27-12-2007 18:59 Pagina 8 CONTENTS Checking for leakage currents . . . . . . Chap. 11 - 5 Removing and reinstalling the battery Chap. 11 - 5 Charging the battery . . . . . . . . . . . . . . Chap. 11 - 5 Filling the battery . . . . . . . . . . . . . . . . Chap. 11 - 6 Checking the voltage regulators . . . . . Chap. 11 - 7 Checking the charging voltage . . . . . . Chap. 11 - 7 CDI unit . . . . . . . . . . . . . . . . . . . . . . . . Chap. 11 - 8 Checking the ignition coil . . . . . .
11_Inghilterra_059311 27-12-2007 18:59 Pagina 9 Checking for leakage currents Check for leakage currents before inspecting the regulator-rectifier. – Disconnect the ignition and remove the earth cable from the battery. – Connect and ampere meter between the earth cable and the negative terminal of the battery. Nominal value: max. 1 mA – If the actual value exceeds the nominal value, proceed to check the various users. Possible malfunctions include: • A faulty regulator-rectifier. • A faulty capacitor.
11_Inghilterra_059311 27-12-2007 18:59 Pagina 10 Filling the battery – Remove the battery and the electrolyte container from the package. Before starting to fill the battery, read through the enclosed instruction slip. – Open the electrolyte container. – Insert the electrolyte container in the battery filler openings and push it down hard. – When all container compartments are empty, remove the container from the battery. – Carefully close the filler openings with the cover.
11_Inghilterra_059311 27-12-2007 18:59 Pagina 11 Checking the voltage regulators If a regulator is suspected of being defective, it should be replaced, if possible, with one that is known to be in working order. Alternatively, take a few measurements to determine whether it is operating properly: – While the engine is off, disconnect the regulator connector located on the frame under the tank. – Use a digital multimeter designed for measurements of up to 20,000 Ω.
11_Inghilterra_059311 27-12-2007 18:59 Pagina 12 CDI unit Check the wires and connectors of the CDI unit. The operation of the CDI unit can only be checked on a specially designed test bench for ignitions. IMPORTANT: NEVER CHECK THE CDI UNIT WITH STANDARD MEASURING EQUIPMENT AS THIS COULD IRREPARABLY DAMAGE HIGHLY SENSITIVE ELECTRONIC COMPONENTS. It is also possible to replace the control unit with one that is known to be in working order to determine whether it is operating properly.
11_Inghilterra_059311 27-12-2007 18:59 Pagina 13 Main fuse Fuse 3 is installed in starting relay 4 under right-hand side panel 5. To gain access to the fuse, remove the saddle and lift swinging support 6 to expose the battery. 5 The fuse protects the following users: – Electric start system. – Horn. – Indicators. – Instrument panel. The starting relay also contains spare fuse 7 (10 A). A blown fuse should only be replaced with another of the same type.
11_Inghilterra_059311 27-12-2007 18:59 Pagina 14 Checking the starter motor – Disconnect the battery negative terminal and remove the starter motor. – Connect the negative terminal of a 12 V battery to the starter motor casing and momentarily connect the battery positive terminal with starter motor connector 3 (use thick cables). – When the electrical circuit is closed, the starter motor should begin to turn. – If that is not the case, replace the starter motor.
